Method and apparatus for making hybrid crude oils and fuels

ABSTRACT

A simplified process is provided for creating hybrid crude oils and hybrid crude fractions with characteristics superior to the original. The process uniquely combines gases with crude oil or crude fractions in an effervescent turbulent manner at low temperatures and pressures and without the further aid of catalysts. The process breaks large chain hydrocarbons into smaller chain hydrocarbons, molecularly combines carbon, hydrogen, and/or hydrocarbon molecules from the gases with and into hydrocarbon molecules of the crude or crude fraction, and separates contaminants and impurities.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/070,450, filed Nov. 1, 2013, which application claims priority toU.S. provisional patent application Ser. No. 61/848,636, filed Jan. 7,2013, which applications are each incorporated herein in their entiretyby this reference thereto.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to crude oil, liquid petroleum fuels, and crudeoil transport. More particularly, the invention relates to a method andapparatus for making hybrid crude oils and fuels.

2. Description of the Background Art

Numerous products are derived from crude oil because of the large numberof hydrocarbon molecules of varying forms, weights, and lengthscontained within, each such product having distinct physical andchemical properties. The mixture of components residing within crude oilis generally categorized as comprising heavy, medium, and lighthydrocarbons, based on the relative molecular weights of each suchcomponent. In the value chain, the medium components provide the mostvalue, followed by the light components, and then the heavy components.The low relative value of the heavy components is reflected in the lowerprices paid for heavy crude as compared to light crude. Higher contentof contaminates and impurities also reduces the value of crude oil. As aresult, efforts have been directed at developing methods to upgrade thevalue of crude oil by converting the heavy components into lightercomponents and extracting contaminants and impurities therefrom.

The large number of components found in crude oil and the complexitiesinvolved in the separation of these components dictate that refineriesbe large in scale. Extraction of crude oil, on the other hand, is widelydispersed and it is therefore necessary to transport the crude oil overlong distances to localized refinery sites. The major mode of crude oiltransportation is pipelines, which presents significant difficulties forheavy crude oil because the associated high viscosity of heavy crude oilreduces its ability to flow. While many methods of reducing theviscosity of heavy crude oil have been devised, demand for an improvedmethodology providing simplification, lower costs, and/or elimination ofchemical additives remains. Without economically and environmentallyviable alternatives for reducing the viscosity of heavy crude, numerouscrude oil sources remain or could become uneconomic.

Reducing the levels of pollution associated with the combustion offossil fuels, i.e. crude fractions, and increasing the mileageassociated with transportation fuels is a major focus of the developedworld. While the primary focus of efforts has been aimed at improvingthe systems and components involved in the combustion of fuels and theexhaust thereof, improvements may also be derived by improving thecharacteristics of the fuels themselves by reducing the average carbonchain lengths and the levels of contaminants and impurities within thefuels.

Many crude oil deposits contain natural gas and other gaseoushydrocarbons that are released from the deposit together with the crudeoil. Because the costs and difficulties of transporting these gases areoften not supported by the revenues that might be generated by its sale,the gas is often vented to the atmosphere or combusted by flare. Withoutan onsite or localized use for these gases, such venting or flaringcomprises a waste of energy resources and added environmental pollution.Use of such resources for productive purposes would create local as wellas larger value.

Methodologies for converting the heavy components of crude oil intolighter components to extract greater economic value have been incontinuous development since the early days of the petroleum industry.Cokers and cracking units of various types use high temperatures, oftenin conjunction with pressure, steam, and/or catalysts to break the heavyhydrocarbon components into lighter hydrocarbon components. Aside fromcokers and cracking units, various techniques are known that use acombination of gases, such as methane or hydrogen, in conjunction withheat, pressure, and/or catalysts of various types to create end productsthat have distillation curves which are shifted downward as compared tothat of the original feedstock.

Several methods for reducing the viscosity of heavy crude oil to improveits flow through pipelines exist, all with attendant issues. Heavy crudeoil can be blended with petroleum-based additives, such as low-viscositycrude oils or crude fractions, but this requires relatively largeamounts of these additives and is feasible only where light crude fieldsor a refinery are nearby. Pipelines themselves can be heated to improvethe flow of heavy oil, but the large capital costs of heating equipmentand insulation, along with ongoing costs of supplying heat, make thislargely uneconomic. Chemical additives can be mixed with crude oil todecrease its viscosity, but the chemicals used are expensive and areretained in the fuels after refining to be released into the atmospherewhen the fuels are burned. As a result of these pollutant issues,refineries are beginning to refuse purchase of crude oils so processed.While there have been various approaches proposed that use methane gasesin conjunction with heat and pressure or catalysts of certain types todecrease the viscosity and raise the API of crude oil, few if any suchtechnologies are being used in the field. The lack of commercialacceptance indicates problems including, but not limited to, scalabilityto the local level, prohibitive capital or operating costs, operationalinefficiencies, and/or limited effectiveness of such approaches.

SUMMARY OF THE INVENTION

An embodiment of the invention disclosed herein provides a simplifiedprocess for breaking large chain hydrocarbon molecules found in crudeoil and crude fractions into smaller chain hydrocarbon molecules, andfor separating contaminants and impurities therefrom. Embodiments of theinvention uniquely combine gases with crude oil or crude fractions in arobust, effervescent manner at relatively low temperatures and pressuresand without the need for further aid of catalysts. Such gases include,but are not limited to, nitrogen, carbon dioxide, carbon monoxide,hydrogen, or hydrocarbons, such as methane, ethane, propane, butane,pentane, ethanol, methanol, or mixtures of two or more thereof, or othercombinations and variations thereof, including field waste gas andnatural gas. Embodiments of the invention increase the proportionalityof higher value middle and light components within crude oil or crudefraction as compared with the original feedstock, i.e. shift ofresulting product distillation curve downward as compared to that of theoriginal feedstock; lower the viscosity of heavy crude oil to improvetransport flow; create crude fractions with improved characteristics;simultaneously remove contaminates and impurities; molecularly combinehydrocarbon gases with the liquid hydrocarbons; and use gases that mightotherwise be wasted.

In general, embodiments of the invention create numerous localized,robust energetic collisions of the gas molecules with the liquidhydrocarbon molecules and ongoing collisions of these molecules within asustained effervescent, turbulent environment. The process is performedat relatively low temperatures and pressures within a self-containednetwork of raw material inflow and product outflow. The effervescentcollision processes take place within a processing vessel in which thegas of choice is turbulently combined with the crude oil or crudefraction liquid by way of nozzles and nozzle placements and/oralignments that best create the direct robustly energetic mixing of thegas molecules with the liquid hydrocarbon molecules, and that sustain anongoing turbulent effervescent interaction of the gas and the liquid asthe gas molecules rise through the liquid. The process generates avaporous off-flow from the top of the liquid that rises to the top ofthe vessel and escapes by way of outlets located on the vessel top. Inan embodiment, the vaporous off-flow is drawn through the outlets by wayof vacuum and further drawn into and through heat exchangers in whichthe gases are cooled. As the gases cool, portions condense to liquidsthat are deposited into a product tank containing the end product. Thegases that do not condense in the cooling process are drawn out of thetop of the product tank and channeled back into the first-stageprocessing vessel to be combined with the liquid crude or crudefraction. As the process proceeds, the very heaviest of the liquidhydrocarbon molecules that are not effectively broken down by theprocess, contaminates, such as sulfur, and impurities, such as sand andwater, settle to the bottom of the processing tank and are periodicallyremoved as required. The results of the interactions include thebreaking down of liquid hydrocarbon molecules into smaller chainhydrocarbon molecules; the molecular combining of gas hydrocarbonmolecules with liquid hydrocarbon molecules; the separation of certainof the heaviest components of the crude oil; and the separation of amaterial portion of the contaminants and impurities contained in thefeedstock.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram that shows the system flow and systemcomponents according to the invention;

FIG. 2 is a block schematic diagram that shows a complete closed loopsystem according to the invention;

FIG. 3 is a top plan view of an example of a gas injection systemaccording to the invention; and

FIGS. 4-8 are test summaries for Tests 1-5

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic diagram that shows the system flow according tothe invention. As shown in FIG. 1, liquid crude oil or crude fraction,i.e. feedstock, (1) is passed through a make pump (2) to a recirculatingpump (3) where the feedstock is mixed with recycled feedstock (21) drawnfrom the upgrader vessel (A).

The feedstock can consist of any type of crude oil, including but notlimited to, heavy, intermediate, light, sour, or sweet, or anycombination thereof, or any crude fraction including, but not limitedto, all types of heavy fuel oils, mineral oils, gasoline, diesel, jetfuels, light fuel oils, naphtha, kerosene, cokes, asphalts, or anycombinations thereof.

The feedstock is then pumped to a circulation heater (4) in which thefeedstock is heated to the appropriate temperature. The heaters can beelectrical, gas, or steam units using conventional heating elements. Gasfrom the locations may be used to create the needed fuel for suchheaters, whether it be electric (gas powered generator), steam (waterheated by gas heater), or gas heaters that are used. The specific typesand sizes of heaters selected are dependent on the best available energysources, the size of the upgrader vessel, and the location of theoperation, i.e. climate, indoor, outdoor. An exemplary embodiment of theinvention uses steam heat. The temperature used depends on the type andcharacteristics of the feedstock and the desired characteristics of theend product. Generally, the temperatures may range between 200 to 450°Fahrenheit, with a more typical range between 240 to 300° Fahrenheit.

The heated feedstock is then fed into the upgrader vessel. Thetemperature of the feedstock within the upgrader vessel is maintainedwithin a desired range, typically +/−1-3° of the optimal temperature ofthe applicable process, by the recirculation of the feedstock (21)through the recirculation pump (3) and the circulation heater (4). Whilethe rate of recirculation varies based on required processingtemperatures of the feedstock and end-product requirements, as well asthe upgrader vessel size, the average rate of recirculation for a 90gallon prototype upgrader vessel is approximately one to four times perminute. The temperature control signals are sent to the heater unitsand/or recirculation pump (3) by way of a system integrator (C). Thesystem integrator consists of commercially available parts withspecially programmed control software.

The upgrader vessel is filled with feedstock to a level providingappropriate open spacing (8) above the feedstock. The size of the openspace (8) depends on the type and characteristics of the feedstock andthe desired characteristics of the end product. Generally, the openspace may range in size from about 5% to about 50% of the total upgradervessel volume, with a more typical range being from 20% to 50%. Anexemplary embodiment of the invention includes a vessel having astraight cylindrical shape, in which the open space as a percentage ofheight is equal to its percentage of volume.

The level of the feedstock within the upgrader vessel is maintainedwithin a desired range by a level measurement device (17) that feeds itsmeasurement signals to the system integrator (C), which controls thepumping system (2). An exemplary embodiment of the invention includes alevel measurement device in which a radar device uses radar signalreturn time to measure the distance from the sensor located at the topof the upgrader vessel to the surface level of the feedstock. The radarlevel sensor signal is fed to the system integrator (C) in conjunctionwith a signal from the residue pump control (22). The residue pumpcontrol alerts the system integrator (C) of the immediacy of residueremoval. Appropriate feedstock levels are maintained by the systemintegrator, using signals provided by both the level measurement device(17) and the residue pump control (22) to generate a feeding controlsignal which is provided to the pumping system (2).

Once the upgrader vessel is filled with feedstock to the appropriatelevel, pressurized gas (5) is sent into and through one or more gasinjection systems (6) at the appropriate pressure into the pool offeedstock contained in the upgrader vessel. The types of gas that may beused include, but are not limited to, nitrogen, carbon dioxide, carbonmonoxide, hydrogen, or hydrocarbon gases such as methane, ethane,propane, butane, pentane, ethanol, or methanol, mixtures of two or morethereof, or other combinations or variations thereof, including fieldwaste gas and natural gas.

In an embodiment of the invention, the pressurized gas (5) used is anon-reactive (non-hydrocarbon) gas, nitrogen, which achieved resultssimilar to embodiments of the invention using hydrocarbon gases propane,methane, and natural gas. In such embodiment, the non-reactive gasinitiates the conversion process resulting in crude and crude fractionvolatiles that are collected at the top of the product vessel (B) andthen directed back to the upgrader vessel, to recycle the gas into thefeedstock under pressure, by a gas injector system (7) that is separatefrom the gas injector system 6 that feeds new pressurized gas (5) intothe upgrader vessel.

The pressure at which the gas is sprayed into the feedstock by way ofthe gas injector system varies depending on the type of gas used and thenumber of nozzles and configurations thereof, as well as the type andcharacteristics of the feedstock and the desired characteristics of theend product. Generally, the pressure may range from about 5 psi to about40 psi, with a more typical range being 12 psi to 25 psi.

The gas flows through one or more gas injection systems and into thefeedstock through nozzles designed to maximize dispersal of forcefuleffervescent collisions of the gas molecules with the liquid feedstockand an ongoing turbulent interaction of the gas with the liquid that issustained as the gas molecules rise through the feedstock.

In embodiments of the invention, the nozzles may be any devices thatdispense the pressurized gas into the feedstock in a manner that createsa streaming, bubbling, or effervescent dispersion of the pressurized gasinto the feedstock. Such devices may include, but are not limited to,various shapes and sizes of openings directly within the piping carryingthe pressurized gas and/or projecting devices of varying materials,shapes, sizes, and flow dynamics that are attached to the pipingcarrying the pressurized gas to better control the direction, speedand/or other characteristics of the gas dispersion.

In embodiments of the invention, the gas injector system is laid out ina horizontal orientation within the upgrader vessel, generally withinthe lower and middle sections of the feedstock pool, but morespecifically, above the space allocated for residue at the bottom of theupgrader vessel and below the top of the feedstock level. The piping ofthe gas injection system is laid out in a grid fashion of any sort tomaximize the distribution of the gaseous infusion streams throughout thefeedstock.

FIG. 2 is a block schematic diagram that shows how embodiments of theinvention can efficiently take crude oil from the well sight using onlylocal components, and create products to feed local distribution of endproducts, such as jet fuel, kerosene, gasoline, and diesels. Because ofthe modular nature of the technology, processing plants can be easilyadapted to the size requirements of individual oil field sights.

Such local components consist of the field waste gas or natural gas, aswell as sun and/or wind that can be harnessed to create electricity. Inaddition to being used within the process itself, the gases can beburned to create steam for the various heating systems required in theprocess, while the electricity produced by wind or solar can be used topower the pumps, meters, control center, and other devices requiringelectricity.

The gases can be captured as they escape the well itself and alsothroughout the process, including from the free water knock out and theheater treater operations, which are used to clean the crude of waterand other contaminates before it is sent on for processing.

FIG. 3 shows an example of a gas injector system according to theinvention. The device consists of piping, through which the pressurizedgas flows, in a round shape (“ring”) that provides the outer ring withconsistent proximity to the inner wall of the cylindrical-shapedupgrader vessel. Within the outer piping ring is a concentric innerpiping ring through which gas also flows. Additional rings can beincluded depending on the upgrader vessel size. In this embodiment ofthe invention, the nozzles are placed on top of the outer and innerpiping rings with even spacing between the groups of nozzles. In anembodiment of the invention, the nozzle groups are placed with threenozzles per group and with pointing angles of the three nozzles suchthat their sprays of pressurized gases collide with one another tocreate additional turbulence. Those skilled in the art will appreciatethat other nozzles arrangements may be used to practice the invention.

The number of gas injection systems depends on the size of the upgradervessel, the type of gas used, and the designs of the gas injectionsystems, as well as the type and characteristics of the feedstock anddesired characteristics of the end product. The gas injector systems maybe stacked one above another, although alternatives may apply.Generally, two to eight gas injection systems may be used, althoughother numbers of gas injection systems may be used in other embodimentsof the invention.

The gas nozzles are mounted to the piping of the gas injector system inmanners to maximize forceful effervescent collisions of the gasmolecules with the liquid feedstock molecules and an ongoing turbulenteffervescent interaction of the gas with the feedstock that is sustainedas the gas molecules rise through the liquid. In embodiments of theinvention, the gas nozzles may be pointed vertically and/or angled in anupward fashion to create a bombardment of the spray of one nozzle intothe spray of one or more other nozzles.

The number of nozzles used depends on the size of the upgrader vesseland type of gas used, as well as the type and characteristics of thefeedstock and desired characteristics of the end product.

One example of an effective gas injection system scheme is shown in FIG.2, which is a top plan view of a gas injection system where pressurizedgas (5) is sent into and through one or more gas injection systems (6)at the appropriate pressure into the pool of feedstock contained in theupgrader vessel. As shown in FIG. 1, as the feedstock reacts with thegas bombardments flowing up through the feedstock, vapors (8) rise fromthe surface of the feedstock and are drawn out through the vapor outflowmanifold (9) and into the heat exchangers (10, 11) where the vapor iscooled.

The number of openings in the vapor outflow manifold and the number ofheat exchangers used is dependent on the size and shape of the upgradervessel and the size of the outflow manifold openings and heatexchangers, as well as the type and characteristics of the feedstock andthe desired characteristics of the end product. The number of openingsin the outflow manifold can range generally from one to five and thenumber of heat exchangers can range generally from one to ten.

The heat exchangers, which can be of many various types, including butnot limited to plated, tube and chill, shell and tube, plate and shell,and plate fin are kept cool by the heat exchanger cold inputs (24) andexchanger outputs (25). As the vapors pass downward through the primaryheat exchangers (10) and then the secondary heat exchangers (11), thevapors are quickly cooled with the cooling causing the formation ofliquid condensates.

The liquid condensates and the gaseous vapors that do not condensate inthe heat exchangers both flow into and through piping (12) that entersthrough and into the top or side of a product vessel (B) with the pipingcontinuing down and through the coalescing media (13) to a point atwhich the condensate and gaseous vapors are discharged into the productvessel (B) below the coalescing media (13) and above highest liquidproduct level.

The liquid condensates fill the lower portion of the product vesselwhile the remaining gaseous vapors rise up and into the coalescing media(13), which coalescing action further cools, condenses, and separatesout any remaining liquid condensate connected to the vapors, whichcondensates then fall into the liquids within the product vessel, whilethe gases, without attached condensate, pass through the coalescingmedia into a space at the top of the product vessel.

In an exemplary embodiment of the invention, the coalescing media (13)is made of stainless steel material shaped in tortuous path routing suchthat it provides a suitable surface for oil droplets to condense on thesurface, then meet and grow, or coalesce, into larger droplets. As theoil droplets grow in size, their weight eventually results in theirdropping into the liquids in the lower portion of the product tank. Thegases passing through the coalescing media are thus more fully separatedfrom remaining liquid hydrocarbons that had not previously condensed outof the gases.

The gases collected at the top of the product vessel are drawn outthrough a gas vent (14) by a compressor and/or blower (15). The gasesare then directed back to the upgrader vessel to recycle the gas througha check valve (16) and into the feedstock under pressure, by a gasinjector system (7) that may be separate from, and may be situatedbelow, the gas injector system 6 that feeds new gas into the upgradervessel. In other embodiments of the invention, these recycled gases maybe combined with new gases and fed into the feedstock in a combinedmanner through gas injector system 6.

The gases that recycle back into the process within the upgrader vesselmay consist of the new gases (5) introduced into the upgrader vessel, aswell as crude and crude fraction volatiles that may separate from thefeedstock and not condensate into the product vessel, and gasespreviously recycled through the system. In an embodiment of theinvention, these gases may consist primarily of C-1 through C-5hydrocarbons, e.g. Pentane having a boiling point of 96° F. and/orHexane having a boiling point of 154° F. Thus, the recycled gasespassing through gas injector system 7 may be different from those newlyintroduced gases (5) passing through gas injector system 6. Because therecycled gases are typically heavier than the new gases (5), gasinjector system 7 may be placed under the new gas delivery injectorsystem 6 to create a more agitative state of the feedstock for thelighter gases introduced above. The heavier gases, because of theirlarge mass and weight, provide for more agitation of the feedstock andbreakage of the hydrocarbon molecules which, in turn, provides moreopportunity for the connection of the lighter hydrocarbon molecules,which contain a relatively higher ratio of hydrogen to carbon molecules,to newly open and available carbon molecules looking for an oppositecharge partner.

Once the product vessel is filled to the maximum level, the level ofliquid within the product vessel is maintained within a desired range byone or more level control switches (18) actuated by a capacitanceswitch. The level control signals, connected via the system integrator(C), govern a motor valve (19) on a liquid product outlet line (20),located at the base of the product vessel, which flows the product toproduct holding tanks.

At the base of the upgrader vessel, a residue of sand, water, sulfur,heavy hydrocarbons, and other contaminants and impurities accumulates(23) and is monitored by a conductivity monitor or a timing device. Asthe accumulation reaches a maximum level, a level control pump (22) isactivated that removes residue from the upgrader vessel. In anembodiment of the invention, the actuator for the level control pump(22) is a specific gravity potentiometer that signals the systemintegrator (C) to actuate the removal of residue by the level controlpump (22) based on characteristics of the feedstock and the operatingparameters being used within the system.

Test Information

Following is a brief discussion of some of the main tests to which crudeand crude fractions are subjected. A brief description of the test isprovided for each test, as well as why the test is of importance inmeasuring.

API Gravity

This is a measure of fuel's specific gravity or density. While specificgravity has no units, density is defined as mass per unit volume andboth are temperature dependent.

API gravity of diesel fuel has a profound effect on engine power. As ageneral rule, there is a 3-5% decrease in the thermal energy content offuel for every ten degree increase in API gravity. This decrease inenergy content results in roughly the same percentage decrease in enginepower. Use of fuels with higher API gravity also results in higher fuelconsumption, e.g. lower MPG.

While there are several scales, generally speaking light, medium, heavy,and extra heavy crude fall within the following API spreads:

-   -   Light crude oil is defined as having an API gravity higher than        31.1° API (less than 870 kg/m³);    -   Medium oil is defined as having an API gravity between 22.3° API        and 31.1° API (870 to 920 kg/m³);    -   Heavy crude oil is defined as having an API gravity below 22.3°        API (920 to 1000 kg/m³); and    -   Extra heavy oil is defined with API gravity below 10.0° API        (greater than 1000 kg/m³).        Flash Point

The flash point temperature is the minimum temperature at which the fuelignites (flashes) on application of an ignition source under specifiedconditions. Flash point varies inversely with the fuel's volatility. Dueto its higher flash point temperature, diesel fuel is inherently saferthan many other fuels, such as gasoline.

Water and Sediment

Fuels should be clear in appearance and free of water and sediment. Thepresence of these materials generally indicates poor fuel handlingpractices. Water and sediment can and do cause shortened filter life orplugged fuel filters, which can, in turn, lead to fuel starvation in theengine. In addition, water can have negative impact on fuel corrosionand on microbial growth.

Distillation

This property provides a measure of the temperature range over which afuel volatilizes or turns to a vapor. Volatility is one of the primaryfactors that distinguish #1 from #2 diesel fuel. No. 1 diesel typicallyhas greater volatility than No. 2. The highest temperature recordedduring distillation is called the end point. Because a fuel's end pointis difficult to measure with good repeatability, the fuel's 90% or 95%distillation point is commonly used.

Kinematic Viscosity

Viscosity affects injector lubrication and fuel atomization. Fuels withlow viscosity may not provide sufficient lubrication. Therefore, fuelsthat do not meet viscosity requirements can lead to performancecomplaints. Fuel atomization is also affected by fuel viscosity. Dieselfuels with high viscosity tend to form larger droplets on injection,which can cause poor combustion and increased exhaust smoke andemissions.

Ash Content

Ash is a measure of the amount of metals contained in the fuel. Highconcentrations of these materials can cause injector tip plugging,combustion deposits, and injection system wear.

Sulfur

To assist diesel engine manufacturers in meeting mandated limits forparticulate matter in diesel engine exhaust, sulfur content is limitedby law to 0.05% for diesel fuel used in on-road applications.

Vapor Pressure

Vapor pressure is an indication of a liquid's evaporation rate. Itrelates to the tendency of particles to escape from the liquid. Asubstance with a high vapor pressure at normal temperatures is oftenreferred to as volatile. Vapor pressures of liquids at ambienttemperatures increase with decreasing boiling points.

Cetane Number/Cetane Index

Cetane number/index is a relative measure of the interval between thebeginning of injection and auto-ignition of the fuel by compression. Thehigher the number, the shorter the delay interval. Fuels with low Cetanenumbers cause hard starting, rough operation, noise, and exhaust smoke.Generally, diesel engines operate better on fuels with Cetane numbersabove 50 compared to fuels with Cetane numbers of the national averageof approximately 45. The Cetane number may be increased through therefining process or the blending of combustion ignition-improvingadditives by fuel suppliers.

Cloud Point

Cloud point is the temperature below which the hydrocarbon liquidbecomes semi-solid and loses its flow characteristics. Cloud pointsrange from 32° C. to below −57° C.

Lubricity

Lubricity describes the ability of a fluid to minimize friction between,and damage to, surfaces in relative motion under loaded conditions.Diesel fuel injection equipment relies somewhat on the lubricatingproperties of the fuel. Shortened life of engine components, such asfuel injection pumps and unit injectors, usually can be ascribed to alack of fuel lubricity and hence is a concern to engine manufacturers.

Types of Carbon Molecules

Crude oil at atmospheric pressure and ambient temperature has three mainconstituents:

-   -   oils, consisting of both saturates and aromatics;    -   resins; and    -   asphaltenes.

These components are analyzed by way of a technique that separatescrude, which has lost its gaseous components, into its four primarycomponents: saturates, aromatics, resins, and asphaltenes. Whilesaturates and aromatics are oils, asphaltenes, and resins are believedto be soluble, chemically altered fragments of the rocks from which theoil was derived as a result of time and high temperatures and pressures.

Saturates/Paraffins are the most stable hydrocarbon molecules. Themolecules have a chemical formula CnH2n+2, indicating that each of thefour electrons of all the carbon atoms of the molecule, which areavailable for bonding, is taken up by a single hydrogen or carbon atom.Because this leaves no electron available for sharing with another atom,paraffin molecules tend to be chemically stable.

Aromatics/Unsaturates are unstable hydrocarbon molecules wherein not allthe electrons on the carbon atoms are bonded to separate carbon orhydrogen atoms; instead, two or three electrons may be taken up by oneneighboring carbon atom, thus forming a “double” or “triple”carbon-carbon bond. Unsaturated hydrocarbon molecules consist of chainmolecules, known as olefins, and ring molecules, known as aromatics.Olefins are typically small in number within crude oil and aromaticstypically make up a larger percentage of the crude oil. Due to theirunstable nature, aromatic/unsaturated molecules can create problemswithin fuels so the percentage of such molecules in fuels may be limitedby design. Such hydrocarbon atoms are often used as solvents.

Resins are C-5 and C-9 aromatic hydrocarbon molecules that are used inindustrial applications due their unique tackifying effects, which isbest suited for use in paint, printing ink, adhesives, rubber, and otherareas where tackiness is required. Generally, the petroleum resins arenot used independently, but have to be used together with other kinds ofresins as promoters, adjusting agents and modifiers in hot meltadhesive, pressure-sensitive adhesive, hot melt road marking paint,rubber tires, and so on.

Asphaltenes make up the heaviest, most viscous components of crude oiland are primarily used as material for road construction, waterproofing,and roofing, and as curing agents and corrosion inhibitors. Because oftheir coagulating nature, asphaltenes are often considered a menace inthe oil field, as well as downstream at the refineries. Becauseasphaltenes are significant constituents of the heavy oils that are nowincreasingly entering the refinery processing streams, refineries mustmake changes to their processing in order to adapt.

Tests

Included herein are the results of the five tests conducted byindependent third party professional laboratories specializing inpetroleum analysis and measurements. The tests are identified as tests1-5, which relates to the sequential order of the tests. The same testswere not completed for each of the tests, and generally speaking, thenumber of tests was increased as the merit of the herein disclosedinvention became more certain and the inventors began looking foradditional information to develop a prototype further.

Test Table #1 includes information from Tests 1-3. The three columns onthe left of the table provide base information. Column 1 provides thenames of the various ASTM (American Society for Testing and Materials)tests used in the testing. Column 2 provides the specific ASTM numberfor each of the tests. Columns 3 and 4 provide the average measurementsfor these tests for standard diesels, #1 and #2, respectively.

Test 1 records the results of the processing #2 diesel with nitrogenand, separately, with natural gas.

The API of the #2 diesel feedstock was 37.7; the Initial Boiling Point(minimum) of the feedstock was measured as 342° F.; the 90% BoilingPoint (maximum) was measured as 695° F.; and the Cetane Index wasmeasured as 52.

After processing with Nitrogen and Natural Gas, the API of the productsmeasured as 38.5 and 42.3; the minimum Boiling Point as 382 and 305° F.;the maximum Boiling Point as 576 and 540° F.; and the Cetane Indexes as42.5 and 35.

Because we are testing for evidence of our lightening crude and crudefractions by way of the cracking of carbon chains, we expected to see anincrease in the API; a decrease in the minimum boiling point; and adecrease in the maximum boiling point. We achieved the increase in APIwith both Nitrogen and Natural Gas; we achieved the decrease in bothminimum and maximum boiling points with the Natural Gas. With respect tothe Nitrogen, we achieved the reduced maximum boiling point butunexpectedly increased the minimum boiling point.

Test 2 records the results of the processing of a Heavy Crude feedstockwith Field Waste Gas being released from the producing wells.

The API of the Heavy Crude feedstock was 11.5; the minimum Boiling Pointof the feedstock was measured as 443° F.; the maximum Boiling Point wasmeasured as 673° F.; the minimum Viscosity (at 40° C.) was measured as375; the sulfur in ppm was measured as 1.7; and the Reid Vapor Pressurewas measured as 0.49.

After processing with Field Waste Gas, tests of the resulting productmeasured the API as 31.4; the minimum Boiling Point as 213° F.; themaximum Boiling Point as 635° F.; the minimum Viscosity was not measured(reason not available); the sediment (in ppm maximum) as 0.400; thewater (in ppm maximum) as 5.60; the ash content % as 0.05; the sulfurcontent (in ppm maximum) as 0.49; and the pour point as <−60° C.

While not all product tests were comparative to Heavy Oil feedstocktests, the comparisons are as follows: the API increased significantlyfrom 11.5 to 31.4; the minimum and maximum Boiling Points decreased from443 to 213 and from 673 to 635; and the sulfur content was reduced from1.7 to 0.49.

Test 3 records the results of the processing of a Light Crude feedstockwith Propane. Three tests were run under varying operating parameters.

The API of the Light Crude feedstock was 34.1; the minimum Boiling Pointof the feedstock was measured as 112.28° F.; the maximum Boiling Pointwas not recorded (reason not provided); the Flash Point (° F.) wasmeasured at 64.4; the minimum Viscosity (at 40° C.) was measured as6.64; the sulfur in ppm was measured as 0.3398; the Cetane Index wasmeasured as 51; and the Lubricity (at 60° C.) was measured as 320.

After processing with Propane in three separate runs, tests of theresulting products measured APIs as 49.3, 50.1, and 45.4; the FlashPoints as 37.4, 32, and 64.4; the minimum Boiling Points as 102.56,99.39, and 102.2° F.; the maximum Boiling Points as 530.42, 551.46, and579.02° F.; the minimum Viscosities as 1.09, 1.08, and 1.27; the sulfurcontents (in ppm maximum) as 0.0251, 0.0387, and 0.0625; the Cetaneindexes as 39, 32.5, and 48.5; the Cloud Points (in ° C.) as −60, −60,and −35; and the Lubricities (at 60° C.) as 420, 450, and 420.

While not all product tests were comparative to Light Oil feedstocktests, the comparisons are as follows: the API increased from 34.1 to49.3, 50.1, and 45.4; the minimum Boiling Points decreased from 112.28to 102.56. 99.39, and 102.2; the Flash Points decreased from 64.4 to37.4, 32, and 64.4; the Viscosity decreased from 6.64 to 1.09, 1.08, and1.27; the copper decreased from 0.3398 to 0.0251, 0.0387, and 0.0625;the Cetane Index declined from 51 to 39, 32.5, and 48.5; and theLubricities increased from 320 to 420, 450, and 420.

Test Table #1 Test #1 DIESEL Test #2 Test #3 DIESEL DIESEL Dec. 12, Dec.12, Dec. 12, Dec. 26, Jan. 25, Feb. 28, Feb. 28, Mar. 11, Mar. 13,Standard Standard 2012 2012 2012 2012 2013 2013 2013 2013 2013 #1-D S15#2-D S15 Feedstock Nitrogen N/G Feedstock W/G Feedstock Propane PropanePropane API Gravity @ 43 39 37.7 38.5 42.3 11.5 31.4 34.1 49.3 50.1 45.460 F. Flash Point F.° 100.4 125.6 — — — — — 64.4 37.4 32 64.4 SedimentPPM max 10 10 — — — — 0.400 — — 0.090 0.010 Water PPM max 200 200 — — —— 5.60 — — — — Distillation temp F.° 90% Volume Recovered: min 336 342382 305 443 213 112.28 102.56 99.39 102.2 max 550.4 671 695 576 540 673635 DNR 530.42 551.46 579.02 Viscosity @ 40° C. min 1.3 1.9 — — — 375 —6.64 1.09 1.08 1.27 max 2.4 4.1 — — — — — — — — — Ash % Content 0.010.01 — — — — 0.05 DNR DNR DNR DNR Sulfur ppm, max 15 15 — — — 1.7 0.490.3398 0.0251 0.0387 0.0625 Sulfur % mass, max 0.05 0.05 — — — — — — — —— Sulfur % mass, max 0.50 0.50 — — — — — — — — — Ried Vapor Pressure — —— — — 0.49 — — — — — Cetane index, min. 45 45 52.0 42.5 35 — — 51 3932.5 48.5 Cloud Point, ° C. varies varies — — — — — — <−60 C.° <−60 C.°<−35 C.° max. Lubricity @ 60° C. 520 520 — — — — — 320 420 450 420Saturates/Paraffins — — — — — — — — — — — Asphaltenes — — — — — — — — —— — Aromaticity, % vol, 35 35 — — — — — — — — — max Resins/Polars — — —— — — — — — — — Pour Point — — — — — — <−60 — — — — Copper Corrosion 3b3b — — — — — DNR DNR DNR DNR max Carbon residue 10% 0.15 0.15 — — — — —DNR DNR DNR DNR

Test Table #2, on the left side, includes results of tests included inTest Table 1 for Tests 4 and 5. On the right side of the table,beginning from the column headed “Hydrocarbon Analysis,” the informationprovides a comparison of the percentage by weight of each of the carbonmolecule sizes (C-6 through C-36+) between the feedstock and the productfor Tests 4 and 5.

On the left side of the table, Test #4 records the results of theprocessing of a Heavy Crude feedstock with Propane and, separately, withMethane.

The API of the Heavy Crude feedstock was measured as 13.5; the minimumand maximum Boiling Points of the feedstock was not measured; the sulfur(as a % of mass, maximum) as 5.3; the Saturates/Paraffins (as apercentage of the weight) as 17.09%; the Asphaltenes (as a percentage ofweight) as 26.76%; the Aromatics (as a percentage of weight) as 14.31%;the Resins/Polars (as a percentage of weight) as 41.84%; and the PourPoint as 18.

While not all product tests were comparative to Heavy Oil feedstocktests, the comparisons are as follows: the APIs increased from 13.5 to31.1 and 25.3; the sulfur declined from 5.3 to 1.5 and 4.2; and the PourPoints declined from 18 to −60 and −35.

With regard to the types of carbon molecules within the Heavy Crudefeedstock compared to the products produced utilizing Propane andMethane, respectively, Saturates/Paraffins increased from 17.09% to31.25% and 41.78%; Asphaltenes decreased from 26.76% to 12.04% and15.00%; Aromatics changes, from the base of 14.31% were mixed, with thePropane product decreasing to 12.51% and the Methane product increasingto 18.71%; Resins/Polars changes, from the base of 41.84% were mixed,with the Propane product increasing to 44.19% and the Methane productdecreasing to 24.50%.

On the left side of the table, Test #5 records the results of theprocessing of a Heavy Crude feedstock with Natural Gas.

The API of the Heavy Crude feedstock was measured as 12.1; the minimumand maximum Boiling Points as 335 and 1098; the Flash point as 115; theSediment (ppm) as 0.300; the Water (ppm) as 1.900; the Viscosity minimumand maximum as 986.9 and 2484; the sulfur (as a % of mass, maximum) as2.9; the Ried Vapor Pressure as 0.90 psi; the True Vapor Pressure as0.58 psi; the Pour Point as 18; the Saturates/Paraffins (as a percentageof the weight) as 40.26%; the Asphaltenes (as a percentage of weight) as15.3%; the Aromatics (as a percentage of weight) as 10.37%; theResins/Polars (as a percentage of weight) as 18%; the Pour Point as 18;and the carbon residue (10%) as 0.90 psi.

While not all product tests were comparative to Heavy Oil feedstocktests, the comparisons are as follows: the API increased from 12.1 to37.2; the sulfur declined from 2.9 to 1.1; the Sediment declined from0.300 to Not Detectable; the Boiling Points minimum and maximum declinedfrom 335 to 246 and from 1098 to 606; the Viscosity minimum and maximumdeclined from 986.9 to 1.330 and 2484 to 30.53; the Ried Vapor Pressureincreased from 0.90 psi to 2.1 psi; the True Vapor Pressure increasedfrom 0.58 psi to 1.2 psi; the Pour Point declined from 18 to −60; andthe Carbon Residue increased from 0.90 psi to 2.1 psi.

With regard to the types of carbon molecules within the Heavy CrudeFeedstock compared to the product, Saturates/Paraffins increased from40.26% to 88.57%; Asphaltenes decreased from 15.37% to 0.38%; Aromaticsdecreased from 33.79% to 4.87%; and Resins/Polars declined from 10.37%to 6.17%.

The right side of the table provides a detailed look at the changes inpercentage weights of each carbon molecule chain length between theFeedstock and the Product.

In Test #4, with Propane, all the light molecules from C-6 to C-16increased as a percentage of weight of the Product as compared to theFeedstock; the C-17 molecules stayed the same at 1.1%; and all theheavier molecules from C-18 to C-36+ decreased.

In Test #4, with Methane, all the light molecules from C-6 to C-17increased as a percentage of weight of the product as compared to thefeedstock; the C-18 molecules decreased; the C-19 molecules increasedfrom 0.90% to 0.97%; and all the heavier molecules from C-20 to C-36+decreased.

In Test #5, all the light molecules from C-6 to C-18 materiallyincreased as a percentage of weight of the product as compare to thefeedstock and all the heavy molecules from C-19 to C-36+ materiallydecreased. The biggest increases in the percentage weight includedmolecules C-11 through C-15, which are important components of diesel.

Test Table #2 Test #4 Test #5 Test #4 Test #5 DIESEL DIESEL Aug. 2, Sep.13, Aug. 2, Sep. 13, Standard Standard 2013 2013 2013 2013 #1-D S15 #2-DS15 Feedstock Propane Methane Feedstock N/G Feedstock Feedstock APIGravity @ 60 F. 43 39 13.5 31.1 25.3 12.1 37.2 1.4 5.2 0.67 0.32 1.8Flash Point F.° 100.4 125.6 98 </=1.72 74 115 </=72 2.0 8.1 3.4 0.43 3.1Sediment PPM max 10 10 — — 100 0.300 ND 2.1 9.5 3.5 0.54 4.5 Water PPMmax 200 200 — — 700 1.900 — 1.9 7.4 4.4 0.56 4.4 Distillation temp F.°90% Volume 1.3 4.7 4.2 0.57 3.6 Recovered: min 336 — — — 335 246 1.3 4.75.2 0.77 8.6 max 550.4 671 — — — 1098 606 1.5 5.0 3.8 0.93 10 1.7 5.14.8 1.5 12 Viscosity @ 40° C. 1.5 3.6 3.4 1.9 10 min 34 35 — — 19 986.91.330 1.4 2.4 2.1 2.2 7.4 max 36 39 — — 40 2484 30.53 1.4 1.8 1.8 2.34.9 1.1 1.1 1.3 2.3 3.1 Ash % Content 0.01 0.01 — — — — — 1.5 1.2 0.851.9 2.1 0.90 0.57 0.97 1.6 1.3 Sulfur ppm, max 15 15 1.4 0.80 0.65 2.81.6 Sulfur % mass, max 5.3 1.5 4.2 2.9 1.1 1.3 0.65 0.74 2.4 0.70 Sulfur% mass, max 0.50 0.50 1.1 0.52 0.49 2.2 0.4 Ried Vapor Pressure — — — —1.5 psi 0.90 psi 2.1 psi 1.5 0.71 0.52 2.0 0.29 True Vapor Pressure — —— — 1.7 psia 0.58 psia 1.2 psia 1.1 0.49 0.62 2.3 0.2 Cetane index, min.45 45 1.3 0.58 0.56 1.9 0.11 1.1 0.49 0.37 2.0 0.062 Cloud Point, ° C.max. varies varies — — — — — 1.0 0.48 0.59 1.7 0.042 1.3 0.59 0.52 1.50.025 Lubricity @ 60° C. 520 520 — — — — — 1.0 0.48 0.52 1.2 0.021 1.20.57 0.52 1.2 0.013 Saturate/Paraffins — — 17.09% 31.25% 41.78% 40.26%88.57% 1.2 0.55 0.52 1.1 0.0078 1.1 0.53 0.54 0.92 0.0064 Asphaltenes —— 26.76% 12.04% 15.00% 15.37%  0.38% 1.0 0.48 0.48 0.84 0.0036 0.94 0.470.47 0.71 0.0043 Aromaticity, % vol, 35 35 14.31% 12.51% 18.71 33.79% 4.87% 0.83 0.43 0.47 0.65 0.0037 max 2.0 1.3 1.1 1.3 0.020Resins/Polars — — 41.84% 44.19% 24.50% 10.37%  6.17% Pour Point — — 18−60 −35.0 18 <−60 Copper Corrosion max 3b 3b — — — — — Carbon residue10% 0.15 0.15 — — — 0.90 psi 21 psi

FIGS. 4-8 are test summaries for Tests 1-5 that provide, at the top ofeach figure, the comparative tests discussed in regard to Test Tables 1and 2, above. In the middle of each figure, the Test Summaries providegraph curve comparisons. Distillation graph curve comparisons areprovided for tests 1, 2, and 3. Carbon Chain graph curve comparison isprovided for test 4. Distillation and Carbon Chain graph curves areprovided for test 5.

Although the invention is described herein with reference to thepreferred embodiment, one skilled in the art will readily appreciatethat other applications may be substituted for those set forth hereinwithout departing from the spirit and scope of the present invention.

For example, embodiments of the invention increase the proportionalityof higher value middle and light components within crude oil as comparedwith the original feedstock, i.e. shift of resulting productdistillation curve downward as compared to that of the originalfeedstock; lower the viscosity of heavy crude oil to improve transportflow; create crude fractions with improved characteristics;simultaneously remove contaminates and impurities; molecularly combinegas hydrocarbon molecules with and into the liquid hydrocarbonmolecules; and use gases in the productive process that might otherwisebe wasted.

Thus, embodiments of the herein disclosed invention find application inupgrading the value of crude oil by converting the heavy components intolighter components, molecularly combining gas hydrocarbons moleculeswith liquid hydrocarbon molecules, and extracting contaminants andimpurities therefrom.

Embodiments of the herein disclosed invention reduce the viscosity ofheavy crude oil and provide an improved methodology that results insimplification, lower costs, and/or elimination of chemical additivesremains. As such, an economically and environmentally viable alternativefor reducing the viscosity of heavy crude is provided, wherein crude oilsources no longer need remain or become uneconomic.

Embodiments of the herein disclosed invention provide improvements inthe characteristics of the fuels themselves. Such improvements arethought to result from shortening the average carbon chain lengthswithin the fuel, which can increase mileage and reduce the fuel'sfreezing point, and by removing sulfurs and other contaminants thatreduce emissions.

Embodiments of the invention address the costs and difficulties oftransporting byproduct gases because such gases are used in practicingthe invention, and need not be vented to the atmosphere, combusted byflare, or pumped back into the wells. Such onsite or localized use ofthese gases for providing heat, steam, electricity, and use within theprocess itself avoids a waste of energy resources and addedenvironmental pollution, and creates local as well as larger value. Inaddition, by the process of the invention, these short-chain gashydrocarbon molecules are combined with longer chain liquid hydrocarbonmolecules in the final product. Such molecular combination increases thevolume of liquid hydrocarbons as compared to the original volume ofcrude or crude fraction feedstock.

Alternative Uses for the Technology

Oil Field Uses

Heavy Crude Extraction

As crude prices rise, many heavy crude oil fields that were shut down asuneconomic are being re-opened. One technology that is used to help liftthe heavy crude is the insertion of diesel or light crude down into thewell to mix with the heavy crude that is being pumped out. The addeddiesel or light crude blends with the heavy crude oil, thus lighteningthe mixed blended crude. Such lightening then increases the amount ofcrude that is extracted as well as minimizes the mechanical problemsassociated with heavy crude. The diesel or light crude must be truckedto and stored at the wellhead location. Embodiment of the invention canbe located at the wellhead location to continuous convert portions ofthe crude production to light crude to insert down into the well as iscurrently being done with diesel or light crude but with a significantcost and environmental advantage.

Powering Wellhead Operations

Fueling the engines for pumps and other equipment, and for creatingelectricity from generators, requires diesel be shipped to the wellheadlocations. Embodiments of the invention can be located at the wellheadlocation to continuous convert portions of the crude production todiesel to support the local need for diesel with a significant cost andenvironmental advantage.

Higher Value Crude

Heavy and extra heavy crude oil typically sells at significantly lowerprices than middle and light crude oil. The reasons include higherpipeline shipping costs, due to heavier corrosion and need for theaddition of chemicals to the oil or heat to the pipeline to allow thecrude to flow, more corrosive materials, internal or added, that need tobe removed before refining, and the lower value composition of thecarbon chains, e.g. large, heavy chains and asphaltenes are not asvaluable to the refineries. Embodiments of the invention can be locatedat the wellhead location to continuous convert the crude oil into highervalue crude so that production revenues increase.

Higher Value Product

Well owners or groups of well owners could form cooperatives or jointventures to use embodiments of the invention to build small, low cost,environmentally friendly refineries to produce and sell value-addedproducts such diesel and gasoline on a local basis to increase revenuesand profits.

Refinery Uses

Refinery Front-End

Refineries could use embodiment of the invention to improve thequalities of the crude oil prior to further processing in the standardmanner. Asphaltenes, which cause increased maintenance and repairs onrefining equipment, could be separated from the other crude components;corrosive components such as sulfurs and copper could be significantlyreduced; the lower value heavy carbon molecules could be reduced bycracking to increase the relative amount of higher value carbonmolecules of the crude;

Refinery Additions

Given the relative cost and environmental advantages of the inventiondisclosed herein, as compared to current refining technologies,refineries could find it more cost effective and easier from aenvironmental permitting prospective to use embodiments of the inventionto increase refining of fuels from crude oil.

Remote/New Refineries

In areas with local availability of crude oil but no refineries, due tothe high financial costs, the large scales required, environmentalissues, or otherwise, refineries based upon embodiment of the inventioncan be built on a smaller scale for lower cost, lower operating costsand logistics, and with less environmental issues. Such areas include,but are not limited to, third world countries that can not affordcurrent technologies; areas of increased oil production developmentwithin the industrialized countries, such as the Bakkens within the U.S.and the Tar Sands in Canada; offshore oil platforms that could produceits fuel requirements from crude oil it is producing rather than pay thehigher costs of having diesel and other fuels shipped to it; militaryoperations that would benefit by having small, local, protectable, andmoveable refining capabilities to avoid the dangers associated withshipping in fuels from outside sources; ships that haul crude oil couldhave onboard refining capabilities to support fuel requirements tominimize fuel stops and reduce costs.

Accordingly, the invention should only be limited by the Claims includedbelow.

The invention claimed is:
 1. A method for breaking large chainhydrocarbon molecules found in crude oil and crude fractions intosmaller chain hydrocarbon molecules, and for separating contaminants andimpurities therefrom, comprising: combining one or more gases with acrude oil or crude fraction feedstock in a turbulent manner attemperatures between 200 to 450° F. and pressures ranging from 5 psi to40 psi within a self-contained network of raw material inflow andproduct outflow to create numerous localized high energy collisions ofgas molecules with liquid hydrocarbon molecules and ongoing collisionsof these molecules within a sustained turbulent environment; with arecirculation pump, pumping said feedstock to a circulation heater toheat said feedstock, wherein said circulation heater comprises any of,an internal heater relative to an upgrader vessel, an external heaterrelative to the upgrader vessel, and a heating of one or more processinggases prior to infusion into upgrader vessel; using nozzles, selectednozzle placements, and nozzle alignments to create said collisionswithin said processing vessel by turbulently combining said gases withsaid crude oil or crude fraction feedstock to force direct high energycollisions of said gas molecules with said liquid hydrocarbon molecules,and to sustain an ongoing turbulent interaction of said gas and saidliquid hydrocarbon molecules as said gas molecules rise through saidliquid hydrocarbon molecules; generating a gaseous off-flow from a topof a liquid that rises to a top of said vessel, said gaseous off-flowescaping via one or more outlets located at said vessel top; drawingsaid gaseous off-flow through said outlets with a vacuum and into andthrough one or more heat exchangers in which said gases are cooled; asthe gases cool, depositing portions thereof that condense to liquidsinto a product tank containing an end product; drawing gases that do notcondense in said cooling step out of the top of the product tank,channeling said gases back into a first stage of said processing vessel,and combining said gases with said liquid crude oil or crude fraction;and periodically removing from said processing tank those liquidhydrocarbon molecules that are not effectively broken down,contaminates, and impurities that settle to a bottom of said processingtank.
 2. The method of claim 1, further comprising: feeding said heatedfeedstock into an upgrader vessel.
 3. The method of claim 1, furthercomprising: maintaining the temperature of said feedstock within saidupgrader vessel within a desired range by recirculating said feedstockthrough said recirculation pump and said circulation heater.
 4. Themethod of claim 1, wherein said method effects breaking large chainhydrocarbon molecules found in crude oil and crude fractions intosmaller chain hydrocarbon molecules and separating of contaminants andimpurities therefrom in the absence of catalysts.
 5. The method of claim1, further comprising any of: shifting a resulting product distillationcurve downward relative to an original feedstock; lowering viscosity ofheavy crude oil to improve transport flow; creating crude fractionshaving improved characteristics; simultaneously removing contaminatesand impurities; and using gases that might otherwise be wasted.
 6. Themethod of claim 1, wherein said gases comprise any of: nitrogen; carbondioxide; carbon monoxide; hydrogen; and hydrocarbons, said hydrocarbonscomprising any of methane, ethane, propane, ethanol, methanol, andmixtures of two or more thereof; natural gas; and combinations of theforegoing.
 7. The method of claim 1, further comprising: passing saidliquid crude oil or crude fraction feedstock through a make pump to arecirculating pump where said feedstock is mixed with recycled feedstockdrawn from an upgrader vessel.
 8. The method of claim 1, said feedstockcomprising any of: heavy, intermediate, light, sour, sweet crude oil,and any combination thereof; and a crude fraction comprising any ofheavy fuel oils, mineral oils, gasoline, diesel, jet fuels, light fueloils, naphtha, kerosene, cokes, asphalts, and any combination thereof.9. The method of claim 1, further comprising: sending temperaturecontrol signals to any of said circulation heater and said recirculationpump via a system integrator.
 10. The method of claim 1, furthercomprising: filling said upgrader vessel with feedstock to a selectedlevel to effect open spacing above said feedstock.
 11. The method ofclaim 10, wherein said open spacing comprises from 5% to 50% of saidupgrader vessel total volume and, more particularly from 20% to 50% ofsaid upgrader vessel total volume.
 12. The method of claim 10, furthercomprising: maintaining said feedstock level within said upgrader vesselwithin a desired range by a level control that is actuated by a leveltransmitter; said level control sending signals are sent to a pumpingsystem via said system integrator.
 13. The method of claim 10, furthercomprising: once said upgrader vessel is filled with feedstock, sendingpressurized gas into and through one or more gas injection systems at aselected pressure into a pool of feedstock contained in said upgradervessel.
 14. The method of claim 13, further comprising: arranging a gasinjector system in a horizontal orientation within said upgrader vessel,within lower and middle sections of said feedstock pool, above a spaceallocated for residue at a bottom of said upgrader vessel, and below atop of said feedstock level.
 15. The method of claim 13, furthercomprising: arranging a gas injector system in a grid fashion tomaximize distribution of gas streams throughout said feedstock.
 16. Themethod of claim 15, further comprising: pointing nozzles of said gasinjector system any of vertically and angled in an upward fashion tocreate a bombardment of a gas stream of one nozzle into a gas stream ofone or more other nozzles.
 17. The method of claim 13, furthercomprising: drawing out vapors that rise from a surface of saidfeedstock, as said feedstock reacts with said gas bombardments flowingup through said feedstock, through a vapor outflow manifold and into oneor more heat exchangers.
 18. The method of claim 17, further comprising:quickly cooling vapors that pass downward through said one or more heatexchangers to form liquid condensates.
 19. The method of claim 18,further comprising: conducting liquid condensates and gaseous vaporsthat do not condensate in said one or more heat exchangers into aproduct vessel; wherein liquid condensates fill a lower portion of saidproduct vessel and remaining gaseous vapors rise into one or more filterseparators.
 20. The method of claim 19, further comprising: drawing gasat a top of said product vessel out through a gas vent and directingsaid gas back to said upgrader vessel through a check valve and intosaid feedstock with a gas injector system.
 21. The method of claim 20,further comprising: once the product vessel is filled to a maximumlevel, maintaining the level of liquid within said product vessel withina desired range via a level control that generates signals which governa valve.
 22. The method of claim 21, further comprising: monitoring aresidue of sand, water, sulfur, heavy hydrocarbons, and othercontaminants and impurities accumulates within said upgrader vessel; andwhen an accumulation reaches a maximum level, opening a gate valve a toallow a certain portion of the residue to exit said upgrader vessel.